CN115374666B - Shot-blasting inherent strain reaction method and system based on deformation release - Google Patents
Shot-blasting inherent strain reaction method and system based on deformation release Download PDFInfo
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- 238000005422 blasting Methods 0.000 title claims abstract description 69
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Abstract
The invention provides a shot-peening inherent strain reaction method based on deformation release, which comprises the following steps: shot peening is performed on a specified area of the standard flat plate sample; measuring the deformation profile of the flat plate after shot blasting, and obtaining the deformation characteristics of the test piece before deformation release; removing part of materials in a specified area on the shot blasting surface of the standard flat plate sample to obtain a sample after deformation release; measuring the geometric profile of the test piece with unequal thickness after removing the material, and obtaining the geometric feature h (x, y) and the deformation feature after deformation release; based on the geometric features and deformation features before and after deformation release, an inherent strain reaction optimization model is established, and inherent strain distribution is optimized and solved. The invention solves the inherent strain based on deformation characteristics, and avoids the problems of complex process, limited precision and the like of the residual stress inverse solution method; compared with a reverse method based on a dynamic impact model, the method remarkably improves the reverse efficiency of the inherent strain, and is an efficient and accurate way for realizing the reverse of the inherent strain of the shot blasting process.
Description
Technical Field
The invention relates to the field of mechanical special machining and surface strengthening, in particular to a shot-peening inherent strain reaction method and system based on deformation release.
Background
The shot peening process is an advanced process widely applied to the manufacturing fields of aerospace, automobiles, high-speed rail cars and the like. The part subjected to surface shot blasting can generate a beneficial residual compressive stress layer on the surface of the part, so that the fatigue resistance of the part is improved, the working life of the part is prolonged, meanwhile, the thin-wall part such as an aviation wallboard and the like can be deformed due to the residual stress introduced by shot blasting, and the deformation can be controlled by controlling shot blasting process parameters such as shot blasting areas, shot blasting paths and the like, so that the method is applied to forming processing. With the technical development, the shot blasting process is developed from traditional mechanical shot blasting to the laser shot blasting which is more flexible and controllable, so that the shot blasting process is added with a new research direction.
Whether conventional mechanical peening or emerging laser peening, the workpiece surface is plastically deformed by peening, thereby introducing residual stresses to improve the fatigue properties of the part or to create desired deformations in the part. The intrinsic strain is the sum of inelastic strains contained in the object, and is the source of residual stress and initial deformation, and the plastic deformation generated in the object in the shot peening process is the shot peening intrinsic strain. Therefore, how to accurately determine the inherent strain of shot peening is of great importance for applications such as shaping control of shot peening and strengthening fatigue life prediction. But there is currently no means to effectively obtain the inherent strain distribution of the shot. The existing application of inherent strain is mainly focused on the welding field, and the application in the shot blasting field is just started, so that related researches are few.
The method for determining the laser shot peening process parameters of the complex curved surface-shaped workpiece by the search CN201510102659.2 is characterized in that an inherent strain method is introduced into a laser shot peening application process plan, but the patent does not explicitly give an acquisition method of the inherent strain parameters; the method for determining the inherent strain of the laser peening through experiments and simulation is provided by searching CN201710829391.1 on the basis of a calculation model, but the method needs to correspond the laser peening parameters to simulation parameters through parameter calibration, the accuracy of the process is difficult to ensure, and the inherent strain distribution correction through the difference between the simulation deformation and the experimental deformation amount often needs repeated iteration and is time-consuming; foreign scholars a.m. korsunsky research laser shot peening inherent strain reaction (Korsunsky AM.Residual elastic strain due to laser shock peening:Modelling by eigenstrain distribution.The Journal of Strain Analysis for Engineering Design.2006;41(3):195-204.) assumes that the total shot peening strain is a linear function, uses a synchronous X-ray diffraction method to directly measure elastic strain, obtains inherent strain values through numerical fitting, but the method is very dependent on measurement precision, the required measurement points are very dense, and the measurement equipment and the measurement process are very expensive, so that popularization and application are difficult to realize; the residual stress (DeWald AT,Hill MR.Eigenstrain-based model for prediction of laser peening residual stresses in arbitrary three-dimensional bodies Part 1:Model description.The Journal of Strain Analysis for Engineering Design.2009;44(1):1-11.), after shot blasting is measured by a contour method by the M.R.Hill et al, and the inherent strain is calculated by the residual stress, but in the method, the residual stress measurement needs to be carried out by cutting a test piece, so that stress redistribution is caused, and the accuracy of the residual stress measurement is limited. The inherent strain of shot blasting has the characteristic of regular and uniform overall distribution, reasonable assumption can be easily made on the distribution of the inherent strain, a clear physical corresponding relation is formed between the inherent strain and deformation characteristics, and the geometric characteristics can be accurately measured by utilizing the existing measuring means. Therefore, the method for acquiring the intrinsic strain of the shot blasting is a shot blasting intrinsic strain acquisition method with wide prospect through the transformation characteristic reaction. In consideration of the fact that the inherent strain and the deformation are not in one-to-one correspondence, the inherent strain distribution cannot be obtained through direct inverse calculation through single deformation, and therefore more inherent strain distribution information is obtained through a deformation release method, and one-to-one correspondence between the inherent strain and the deformation is established.
In view of the foregoing, it is important to obtain an accurate intrinsic strain distribution in a shot peening process, but there is still a lack of an effective method for obtaining an intrinsic strain of shot peening, so that an accurate and effective method is needed to counter the intrinsic strain of shot peening.
Disclosure of Invention
In view of the defects in the prior art, the invention aims to provide a shot peening inherent strain reaction method based on deformation release.
The invention provides a method for solving the inherent strain of shot blasting based on deformation release, which comprises the following specific steps:
step 1: performing shot blasting treatment on the designated area of the standard flat test piece by using given shot blasting process parameters to enable the test piece to generate shot blasting deformation;
Step 2: measuring the deformation profile of the flat plate after shot blasting, and obtaining the deformation characteristics of the test piece before deformation release;
step 3: the material removing treatment is carried out on the surface of the shot blasting side to enable the test piece to deform and release;
Step 4: measuring the geometric profile of the test piece with unequal thickness after removing the material;
Step 5: obtaining three-dimensional geometric characteristics of the test piece after deformation release through the point cloud matching pair Ji Dianyun, and obtaining the geometric characteristics and the deformation characteristics after deformation release;
Step 6: carrying the geometric features and deformation features of the test piece before and after deformation release into an inherent inverse optimization model to solve;
Step 7: and (5) obtaining the inherent strain distribution parameters after the optimization is finished, and completing the inherent strain reaction.
Preferably, the deformation characteristic of the test piece before the deformation release in the step 2 is deformation displacement d 0 generated by the flat test piece after shot blasting.
Preferably, the material removal process in the step 3 is wire cutting or chemical etching.
Preferably, the geometric profile of the test piece with different thickness after removing the material in the step 4 refers to the point cloud profile S u,Sl of the upper and lower surfaces of the test piece.
Preferably, the geometric feature after deformation release in the step 5 is that the relative position between the upper surface profile and the lower surface profile, namely the thickness distribution h (x, y) of the plate is calculated through point cloud matching, and the deformation feature after deformation release is that the deformation displacement d 1 of the lower surface.
Preferably, the inherent strain reaction optimization model in the step 6 is implemented by using the actual deformation displacement d 0,d1 and the theoretical deformation displacement before and after material removalThe error of (2) is an objective function, and an optimization model established by taking an inherent moment theoretical equation and an empirical parameter interval function as constraints is expressed as follows:
Wherein gamma is super parameter, gamma epsilon (0, 1) is used for adjusting the importance degree of deformation error before and after removing material in the objective function, S is the feasible domain of inherent strain distribution parameter determined by the related engineering experience of the shot blasting process, t is the standard test piece thickness, To remove the intrinsic moment before material,/>To remove the inherent moment after the material, K 0 is the finite element overall stiffness matrix before the material is removed, K 1 is the finite element overall stiffness matrix after the material is removed, λ 0 is the inherent moment equivalent load coefficient before the material is removed, and λ 1 is the inherent moment equivalent load coefficient after the material is removed.
Preferably, the inherent moment theoretical equation refers to a finite element control equation obtained by discretizing a partial differential control equation between inherent moment and deformation derived according to a plate shell bending theory, and the equation is:
where K is the finite element overall stiffness matrix, For theoretical deformation, λ is the moment equivalent load coefficient and N * is the moment.
Preferably, the calculation formula of N * is:
Wherein h (x, y) is the thickness distribution of the test piece, t is the original thickness of the test piece, alpha is an unknown parameter vector of the inherent strain distribution to be reversely calculated, and alpha epsilon S, z is the depth along the normal direction of the shot blasting surface.
Preferably, the theoretical deformation displacementBy assuming a functional form of the distribution of the intrinsic strain in the depth direction such as epsilon *＝ε* (z; alpha), and then calculating based on the intrinsic moment theory.
Preferably, the function of the distribution of the intrinsic strain in the depth direction is an empirically determined function of band parameters, such as Gaussian distribution, for approximating the intrinsic strain distribution of shot peeningWhere α= (a, b, c, k) is an unknown parameter vector of the intrinsic strain distribution to be reversed, and z is the depth along the normal of the peened surface.
According to the invention, the shot-peening inherent strain reaction system based on deformation release comprises:
Module M1: performing shot blasting treatment on the designated area of the standard flat test piece by using given shot blasting process parameters to enable the test piece to generate shot blasting deformation;
Module M2: measuring the deformation profile of the flat plate after shot blasting, and obtaining the deformation characteristics of the test piece before deformation release;
module M3: the material removing treatment is carried out on the surface of the shot blasting side to enable the test piece to deform and release;
module M4: measuring the geometric profile of the test piece with unequal thickness after removing the material;
Module M5: obtaining three-dimensional geometric characteristics of the test piece after deformation release through the point cloud matching pair Ji Dianyun, and obtaining the geometric characteristics and the deformation characteristics after deformation release;
module M6: carrying the geometric features and deformation features of the test piece before and after deformation release into an inherent inverse optimization model to solve;
module M7: and (5) obtaining the inherent strain distribution parameters after the optimization is finished, and completing the inherent strain reaction.
Compared with the prior art, the invention has the following beneficial effects:
(1) The optimized model established by the inherent moment theory reflects the relation between the inherent strain and the deformation more essentially, and the reversed inherent strain has more practical physical significance, and can be used for shot peening forming prediction and construction of shot peening residual stress in shot peening strengthening;
(2) According to the invention, the inherent strain is solved through the deformation characteristics, the deformation is easier to measure than the strain or stress, the measurement efficiency is higher, the deformation can be measured rapidly and accurately by means of high-precision measurement equipment, and the inherent strain is solved effectively;
(3) According to the invention, the inherent strain reaction can be realized only according to the deformation geometric characteristics generated by shot blasting, the laser shot blasting parameters do not need to be calibrated, and the simulation iteration is not needed, so that the operation is simple and convenient, and the solving efficiency is high.
Drawings
Other features, objects and advantages of the present invention will become more apparent upon reading of the detailed description of non-limiting embodiments, given with reference to the accompanying drawings in which:
FIG. 1 is a flow chart of the intrinsic strain reaction of the present invention;
FIG. 2 is a schematic diagram of the full-coverage laser peening clamping in embodiment 1 of the present invention;
FIG. 3 is a schematic view showing the release deformation of the removed material in example 1 of the present invention;
FIG. 4 shows the result of point cloud matching after material removal in example 1 of the present invention;
FIG. 5 is the result of the intrinsic strain reaction in example 1 of the present invention;
Fig. 6 is a verification result of the reaction of the intrinsic strain in the embodiment 1 of the present invention, wherein a is deformation verification and b is residual stress verification.
Detailed Description
The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the present invention, but are not intended to limit the invention in any way. It should be noted that variations and modifications could be made by those skilled in the art without departing from the inventive concept. These are all within the scope of the present invention.
Example 1
FIG. 1 is a flow chart of the inherent strain reaction of the present invention, which specifically includes the following steps:
step 1: performing shot blasting treatment on the specified area of the standard flat test piece by using given shot blasting process parameters to enable the test piece to generate shot blasting deformation, wherein the thickness of the standard test piece is t;
Step 2: measuring deformation displacement d 0 of the standard flat test piece after shot blasting;
step 3: the material removing treatment is carried out on the surface of the shot blasting side to enable the test piece to deform and release;
Step 4: measuring point clouds u,Sl of the surface profiles of the shot side and the non-shot side of the test piece after deformation release to obtain surface geometric characteristics;
Step 5: obtaining three-dimensional geometric characteristics of the test piece after deformation release through the point cloud matching pair Ji Dianyun, and obtaining the thickness h of the plate after deformation release and the deformation displacement d 1;
Step 6: assuming that the distribution of inherent strain of shot blasting obeys a certain function form epsilon *＝ε* (z; alpha) containing unknown parameters, bringing the geometric features t and h of the test piece before and after deformation release and the deformation feature d 0,d1 into an optimized parameter optimization model, and calling an optimized solving program to solve;
Step 7: and (5) obtaining an inherent strain distribution parameter alpha after the optimization is finished, and completing the inherent strain reaction.
In the embodiment, the shot blasting mode is laser shot blasting, the standard flat plate test piece is a square plate with the thickness of 100x100x4mm 3, the material is 2024-T351 aluminum alloy, the specified shot blasting area is full-coverage laser shot blasting, the specified laser shot blasting parameter is 10J, the spot size is 4mm, the pulse width is 15ns, the absorption layer is a black tape, the constraint layer is water, and the test piece clamping mode is shown in figure 2. After shot blasting, the deformation displacement on the two central axes of the standard flat plate is measured by using a three-dimensional surface morphology instrument, and the measured deformation displacement d 0 of the flat plate before removing the material can be obtained through numerical fitting according to the deformation of the plate behind the full-coverage shot blasting into a paraboloid.
As shown in fig. 3, by means of layer-by-layer micro milling, part of the material on the surface of the test piece after shot blasting is removed under the condition of minimal processing influence, deformation is released, after the material is removed, the three-dimensional surface topography instrument is used for measuring the point cloud outlines on the upper surface and the lower surface of the flat plate, the surface topography is obtained, and as the offset of the upper surface and the lower surface at the corner points of four corners is known, the relative positions of the two point clouds in space can be obtained through point cloud matching, as shown in fig. 4. The geometric shape of the test piece after the material is removed can be obtained from the relative position of the point cloud in space, and the deformation displacement d 1 of the test piece after the material is removed can be obtained by aligning the center point of the non-shot-blasted surface to the origin of coordinates.
Theoretical deformation is calculated by the inherent moment theory: first calculate cell stiffness matrixWherein/>Is a unit strain matrix, is related to unit types, D b is a rigidity coefficient matrix, is related to material parameters and test piece geometry,
Wherein h is the thickness of the plate at the unit, h=t=4mm before removing the material, and the thickness distribution h (x, y) obtained by matching the point cloud after removing the material can be determined; e is the elastic modulus of the material; μ is the poisson's ratio of the material. The overall stiffness can be assembled from the cell stiffness matrix.
The present embodiment assumes that the intrinsic strain distribution is Gaussian, and that the intrinsic strain in the peening direction differs from that in the perpendicular peening direction by a factor, i.eIntrinsic moment is/> H (x, y) is the thickness distribution of the test piece (h (x, y) =t before removing material), as shown in the figure (only one direction is drawn), λ is the matrix of intrinsic moment equivalent load coefficients, determined by the material parameters and cell type, determined by/>The theoretical deformation expression/>, which contains unknown parameters, can be obtained
Finally, willD 0,d1 is substituted into an optimization model, the super parameter gamma is 0.2, the feasible region S is a epsilon [0,0.02], b epsilon [0,5], c epsilon [0.001,5], k epsilon [0,5] according to the experience of laser peening engineering, the inherent strain distribution parameter is obtained by optimizing and solving by using an interior point method, and the inherent strain of the laser peening is determined. The final inversion results are shown in table 1 below:
TABLE 1 inherent strain distribution parameter inversion results
| a | b | c | k |
| 0.0051 | 0.24 | 0.96 | 0.71 |
The result of the reaction of the intrinsic strain in this embodiment is shown in fig. 5, and the result of the verification of the reaction of the intrinsic strain is shown in fig. 6, wherein a is the deformation verification, and b is the residual stress verification.
Example 2
A system for countering intrinsic strain of shot peening based on deformation relief, comprising:
Module M1: performing shot blasting treatment on the designated area of the standard flat test piece by using given shot blasting process parameters to enable the test piece to generate shot blasting deformation;
Module M2: measuring the deformation profile of the flat plate after shot blasting, and obtaining the deformation characteristics of the test piece before deformation release;
module M3: the material removing treatment is carried out on the surface of the shot blasting side to enable the test piece to deform and release;
module M4: measuring the geometric profile of the test piece with unequal thickness after removing the material;
Module M5: obtaining three-dimensional geometric characteristics of the test piece after deformation release through the point cloud matching pair Ji Dianyun, and obtaining the geometric characteristics and the deformation characteristics after deformation release;
module M6: carrying the geometric features and deformation features of the test piece before and after deformation release into an inherent inverse optimization model to solve;
module M7: and (5) obtaining the inherent strain distribution parameters after the optimization is finished, and completing the inherent strain reaction.
Those skilled in the art will appreciate that the invention provides a system and its individual devices, modules, units, etc. that can be implemented entirely by logic programming of method steps, in addition to being implemented as pure computer readable program code, in the form of logic gates, switches, application specific integrated circuits, programmable logic controllers, embedded microcontrollers, etc. Therefore, the system and various devices, modules and units thereof provided by the invention can be regarded as a hardware component, and the devices, modules and units for realizing various functions included in the system can also be regarded as structures in the hardware component; means, modules, and units for implementing the various functions may also be considered as either software modules for implementing the methods or structures within hardware components.
The foregoing describes specific embodiments of the present application. It is to be understood that the application is not limited to the particular embodiments described above, and that various changes or modifications may be made by those skilled in the art within the scope of the appended claims without affecting the spirit of the application. The embodiments of the application and the features of the embodiments may be combined with each other arbitrarily without conflict.
Claims (4)
1. The method for solving the inherent strain of the shot blasting based on deformation release is characterized by comprising the following specific steps of:
step 1: performing shot blasting treatment on the designated area of the standard flat test piece by using given shot blasting process parameters to enable the test piece to generate shot blasting deformation;
Step 2: measuring the deformation profile of the flat plate after shot blasting, and obtaining the deformation characteristics of the test piece before deformation release;
step 3: the material removing treatment is carried out on the surface of the shot blasting side to enable the test piece to deform and release;
Step 4: measuring the geometric profile of the test piece with unequal thickness after removing the material;
Step 5: obtaining three-dimensional geometric characteristics of the test piece after deformation release through the point cloud matching pair Ji Dianyun, and obtaining the geometric characteristics and the deformation characteristics after deformation release;
Step 6: carrying the geometric features and deformation features of the test piece before and after deformation release into an inherent inverse optimization model to solve;
step 7: obtaining inherent strain distribution parameters after optimization is finished, and completing inherent strain reaction;
The deformation characteristic of the test piece before deformation release in the step 2 is deformation displacement generated by the flat test piece after shot blasting ；
The geometrical characteristics after deformation release in the step 5 are that the relative position between the upper surface profile and the lower surface profile is calculated through point cloud matching, namely the thickness distribution of the test pieceThe deformation characteristic after deformation release is deformation displacement/>, of the lower surface；
The inherent strain in step 6 is reflected in an optimization model，/>And theoretical deformation displacement/>，/>The error of (2) is an objective function, and an optimization model established by taking an inherent moment theoretical equation and an empirical parameter interval function as constraints is expressed as follows:
Wherein the method comprises the steps of Is super-parameter,/>For adjusting the importance of deformation errors before and after removal of material in an objective function,/>To remove the intrinsic moment before material,/>To remove intrinsic moment after material,/>To remove the finite element overall stiffness matrix before material,/>To the finite element overall stiffness matrix after material removal,/>To remove intrinsic moment equivalent load coefficient before material,/>Equivalent load coefficient for intrinsic moment after material removal;
The inherent moment theoretical equation is a finite element control equation obtained by discretizing a partial differential control equation between inherent moment and deformation deduced according to a plate shell bending theory, and the inherent moment theoretical equation is: ，
Wherein the method comprises the steps of Is a finite element overall stiffness matrix,/>For theoretical deformation,/>Is the equivalent load coefficient of the inherent moment,/>Is an inherent moment;
The said The calculation formula is as follows: /(I)，
Wherein the method comprises the steps ofFor the thickness distribution of the test piece,/>For the original thickness of the test piece,/>Is an unknown parameter vector of the intrinsic strain distribution to be negated and a e S, S is a feasible region of the intrinsic strain distribution parameter determined empirically from the relevant engineering of the peening process, z is the depth along the normal of the peening surface,/>Is a distribution function of the inherent strain along the depth direction;
said theoretical deformation displacement ，/>Distribution function/>, along depth direction, by intrinsic strainCalculating and obtaining an inherent moment theory;
the distribution function of the inherent strain along the depth direction is a band parameter function which is empirically determined and used for shot blasting inherent strain distribution, and the band parameter function is Gaussian distribution ，/>WhereinFor an unknown parameter vector of the intrinsic strain distribution to be negated,/>Is the depth along the normal direction of the peened surface.
2. The method according to claim 1, wherein the material removal process in step 3 is wire cutting or chemical etching.
3. The method according to claim 1, wherein the geometric profile of the test piece with unequal thickness after removing the material in the step 4 is a point cloud profile S u, Sl of the upper and lower surfaces of the test piece.
4. A system for counteracting intrinsic strain of shot-peening based on deformation relief, comprising:
Module M1: performing shot blasting treatment on the designated area of the standard flat test piece by using given shot blasting process parameters to enable the test piece to generate shot blasting deformation;
Module M2: measuring the deformation profile of the flat plate after shot blasting, and obtaining the deformation characteristics of the test piece before deformation release;
module M3: the material removing treatment is carried out on the surface of the shot blasting side to enable the test piece to deform and release;
module M4: measuring the geometric profile of the test piece with unequal thickness after removing the material;
Module M5: obtaining three-dimensional geometric characteristics of the test piece after deformation release through the point cloud matching pair Ji Dianyun, and obtaining the geometric characteristics and the deformation characteristics after deformation release;
module M6: carrying the geometric features and deformation features of the test piece before and after deformation release into an inherent inverse optimization model to solve;
module M7: obtaining inherent strain distribution parameters after optimization is finished, and completing inherent strain reaction;
The deformation characteristic of the test piece before deformation release in the module M2 is deformation displacement generated by the flat test piece after shot blasting ；
The geometrical characteristics after deformation release in the module M5 are that the relative positions between the upper surface profile and the lower surface profile are calculated through point cloud matching, namely the thickness distribution of a test pieceThe deformation characteristic after deformation release is deformation displacement/>, of the lower surface；
Inherent strain in module M6 is reflected in an optimization model，/>And theoretical deformation displacement/>，/>The error of (2) is an objective function, and an optimization model established by taking an inherent moment theoretical equation and an empirical parameter interval function as constraints is expressed as follows:
Wherein the method comprises the steps of Is super-parameter,/>For adjusting the importance of deformation errors before and after removal of material in an objective function,/>To remove the intrinsic moment before material,/>To remove intrinsic moment after material,/>To remove the finite element overall stiffness matrix before material,/>To the finite element overall stiffness matrix after material removal,/>To remove intrinsic moment equivalent load coefficient before material,/>Equivalent load coefficient for intrinsic moment after material removal;
The inherent moment theoretical equation is a finite element control equation obtained by discretizing a partial differential control equation between inherent moment and deformation deduced according to a plate shell bending theory, and the inherent moment theoretical equation is: ，
Wherein the method comprises the steps of Is a finite element overall stiffness matrix,/>For theoretical deformation,/>Is the equivalent load coefficient of the inherent moment,/>Is an inherent moment;
The said The calculation formula is as follows: /(I)，
Wherein the method comprises the steps ofFor the thickness distribution of the test piece,/>For the original thickness of the test piece,/>Is an unknown parameter vector of the intrinsic strain distribution to be negated, and a e S, S is a feasible region of the intrinsic strain distribution parameter determined from the relevant engineering experience of the peening process,/>For depth along normal to the peened surface,/>Is a distribution function of the inherent strain along the depth direction;
said theoretical deformation displacement ，/>Distribution function/>, along depth direction, by intrinsic strainCalculating and obtaining an inherent moment theory;
the distribution function of the inherent strain along the depth direction is a band parameter function which is empirically determined and used for shot blasting inherent strain distribution, and the band parameter function is Gaussian distribution ，/>WhereinFor an unknown parameter vector of the intrinsic strain distribution to be negated,/>Is the depth along the normal direction of the peened surface.
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